Download
Share
Print this page
Weil-McLain 4 Series Manual
  1. Manuals
  2. Brands
  3. Weil-McLain Manuals
  4. Boiler
  5. Series 4
  6. Manual

Weil-McLain 4 Series Manual

Gas-fired water boilers
Hide thumbs Also See for 4 Series:

Advertisement

Quick Links

See also: User's Information Manual
®
Gas-fi red water boilers – Series 4
Featuring
®
Flexibility
Boiler Manual
®
This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including this manual and
all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
Part number 550-100-400/0119

Advertisement

loading
Need help?

Need help?

Do you have a question about the 4 Series and is the answer not in the manual?

Questions and answers

Related Manuals for Weil-McLain 4 Series

Summary of Contents for Weil-McLain 4 Series

  • Page 1 ® Gas-fi red water boilers – Series 4 Featuring ® Flexibility Boiler Manual ® This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 2 ® Series 4 GAS-FIRED WATER BOILER Contents Ultra at-a-glance ....2 (see page 44 and page 46 for details of all models) ....4 .
  • Page 3 This section covers basic installation and start-up for most applications. It is limited to Pages Procedure conventional systems and to sidewall vent/ air piping using the Weil-McLain termina- Please read before proceeding tion cap. • Read safety information before proceeding For applications not covered in this sec-...
  • Page 4 See the instructions contact with water, replace the boiler with a new Weil-McLain boiler. at right. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
  • Page 5 2. Boilers can be wall mounted ONLY if using the optional 2. Vent pipe — at least ” from combustible materials. 3/16 wall-mount kit available from Weil-McLain. See page 50 3. See Figure 1 for other clearance minimums. for instructions. Part number 550-100-400/0119...
  • Page 6 ® Series 4 gas-fired water boiler — Boiler Manual Prepare boiler location (continued) Flooring and foundation Provide air openings to room Air openings — Ultra boiler alone in boiler Flooring room The Ultra boiler is approved for installation on combustible fl ooring, 1.
  • Page 7 1. The Ultra boiler is generally easier to handle and maneuver after 1. Boilers can be wall mounted ONLY if using the optional removing from crate. wall-mount kit available from Weil-McLain. See page 50 for instructions. 2. After removing outer shipping carton from boiler, REMOVE jacket front door by loosening two (2) screws at lower front.
  • Page 8 ® Series 4 gas-fired water boiler — Boiler Manual Prepare boiler (continued) Figure 2 . This is the maximum allowable relief valve setting for the Ultra boiler. Perform hydrostatic pressure test Pressure test boiler before permanently attaching water or gas piping or electrical supply.
  • Page 9 Replacement parts section at the end of this manual for connections to prevent them from turning could cause the Weil-McLain low water cut-off kit. damage to boiler components. 4. Purchase low water cutoff and install in a tee in the supply piping above boiler.
  • Page 10 Figure 3 . ing system. For other piping methods, consult your local Weil-McLain representative or see separate Ultra boiler piping guides. a. Determine the heating load (Btuh) for each circuit.
  • Page 11 Ultra-155, 230 DO NOT use a closed-type expansion tank on a system 1¼” Ultra-299/310, with a Weil-McLain AQUA PLUS water heater. The water 1½” heater must use an automatic air vent. Operation of the See CAUTION at left. automatic air vent will deplete air in the piping, causing the expansion tank to waterlog.
  • Page 12 ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — typical systems Zoning with zone valves Figure 5 1. Connect boiler to system as shown in Figure 5 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have suffi...
  • Page 13 ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — typical systems (continued) Zoning with circulators Figure 6 1. Connect boiler to system as shown in Figure 6 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop.
  • Page 14 (optional timeout setting can be used to override). DO NOT use a closed-type expansion tank on a system with a Weil-McLain AQUA PLUS water heater. The water heater must use an automatic air vent. Operation of the automatic air vent will deplete air in the piping, causing the expansion tank to waterlog.
  • Page 15 ® Series 4 gas-fired water boiler — Boiler Manual Using with Weil-McLain AQUA PLUS water heaters (cont.) Figure 10 Boiler loop pipe size Ultra-80, -105 1” or larger Ultra-155, -230 1¼” or larger For residential space heating appli- cations (other than radiant heating Ultra-299/310, 399 1½...
  • Page 16 ® Series 4 gas-fired water boiler — Boiler Manual Venting/air piping — general Do not install the Ultra boiler into a common vent with any other appliance. This will cause fl ue gas spillage or ap- — Install air inlet piping for the Ultra pliance malfunction, resulting in possible severe personal boiler as described in the Boiler manual and this ad- injury, death or substantial property damage.
  • Page 17 ® Series 4 gas-fired water boiler — Boiler Manual Venting/air piping — general (continued) Combustion air piping 1. Combustion air must be piped from outside to the boiler, following the instructions in this manual, and compliant with all applicable codes. Read the warning in Figure 11, page 16, and ensure the air intake will not be likely to draw in con- taminated air.
  • Page 18 System 636. When using IPEX kits, use only IPEX product code 196006 for 3” venting or IPEX product code 196021 for 4” Note 1: venting. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits. Polypropylene - Separate pipe and concentric termination by respective manufacturers. a — Use 3”x2” reducer at boiler c —...
  • Page 19 AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection and at the termination (when using Weil-McLain plate or concentric PVC termination). DO NOT mix piping from different vent pipe manufacturers unless using adapters specifi cally designed for the purpose by the manufacturer.
  • Page 20 Allowable vent/air pipe materials Figure 14 1. Use only the materials listed in Figure 13, page 19 . 2. The Weil-McLain vent termination kit includes inside and outside wall plates, bird screens, and mounting hardware to secure the plates (kit included with boiler).
  • Page 21 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: Separate pipes (continued) 4. You must consider the surroundings when terminating the vent Figure 16 and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.
  • Page 22 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: Separate pipes (continued) Multiple vent/air terminations Figure 19 1. When terminating multiple Ultra boilers, terminate each vent/air connection as described in this manual. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death or substantial property damage.
  • Page 23 ® Series 4 gas-fired water boiler — Boiler Manual Vertical vent/air termination: Separate pipes Allowable vent/air pipe materials Figure 21 1. Use only the materials listed in Figure 13, page 19 . 2. Purchase bird screens for vent and air terminations separately. See the parts list at the end of this manual.
  • Page 24 ® Series 4 gas-fired water boiler — Boiler Manual Vertical vent/air termination: Separate pipes (continued) 5. Maintain clearances to vent termination as given below: Figure 23 a. Vent must terminate: At least 6 feet from adjacent walls. No closer than 5 feet below roof overhang. At least 7 feet above any public walkway.
  • Page 25 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT VENT Figure 24 DIRECT VENT DIRECT VENT DIRECT VENT DIRECT VENT VERTICAL vent and SIDEWALL termination VERTICAL termination SIDEWALL air Step 1 Install the boiler. Step 2 Determine the termination method — sidewall or vertical, concentric or separate pipes, etc. Step 3 Determine proper location for wall or roof penetration for each termination.
  • Page 26 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT EXHAUST Figure 25 DIRECT EXHAUST DIRECT EXHAUST DIRECT EXHAUST Sidewall termination Vertical termination Install the boiler. Step 1 Determine the proper location for roof or wall penetration for each termination. Step 2 Prepare roof penetrations before installing vent piping.
  • Page 27 ® Series 4 gas-fired water boiler — Boiler Manual Install condensate line Prepare condensate fi ttings Figure 26 1. Remove PVC fi ttings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” x 1¼” PVC nipple to ensure even cement distribution when joining.

  • Page 28: Table Of Contents

    (typically with a pH from 3.2 to 4.5). Install a neutralizing fi lter if required by local codes. See Replacement parts section at the end of this manual for the Weil-McLain kit. Figure 29 Figure 32 Minimum recommended condensate pump...

  • Page 29: Figure 33

    ® Series 4 gas-fired water boiler — Boiler Manual Gas piping Connecting gas supply piping Use two wrenches when tightening gas 1. Remove jacket front panel and refer to Figure 33 to pipe gas to piping at boiler, using one wrench to pre- boiler.
  • Page 30 ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — basic system Wiring must be N.E.C. Class 1. If original wiring — For your as supplied with boiler must be replaced, use only safety, turn off electrical power supply at service type 105 °C wire or equivalent.

  • Page 31: Figure 34

    ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — basic system (continued) Figure 34 Locate the sensors on the system piping as shown in Figure 4, page 11 and other piping drawings throughout this manual. — see the ADVANCED INSTALLATION section of this manual.

  • Page 32: Figure 35

    ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup Figure 35 — You must ensure that the U- Control is set for the proper water temperatures for the (also see Figure 36, page 33 ) system. Excessive water temperature can cause signifi cant property damage in some applications.
  • Page 33 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup (continued) Figure 36 (see Figure 114, page 101 ) (see Figure 114, page 101 ) Part number 550-100-400/0119...
  • Page 34 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup (continued) EXPRESS SETUP — using default settings 1. The U-Control is factory programmed to supply a DHW circuit (control , see the priority 1) and fi nned tube baseboard space heating (control priority 2). ADVANCED INSTALLATION 2.
  • Page 35 Antif reeze 1. You must thoroughly flush the system (without boiler 1. Use only antifreeze listed by Weil-McLain as suitable for use connected) to remove sediment. The high-effi ciency heat with Ultra Gas Boilers. A list of approved antifreeze products exchanger can be damaged by buildup or corrosion due to is available at www.Weil-McLain.com.
  • Page 36 . Use only water and verify inhibitor concentration. freeze-prevention fl uids recommended by Weil-McLain for application in Ultra Check inhibitor concentration annually Boiler systems. 1. Test the pH of a sample of system water at least annually. The pH of before installing the the water mixture must be between 7.0 and 8.5.
  • Page 37 ® Series 4 gas-fired water boiler — Boiler Manual Startup — fi nal checks Inspect/fi ll condensate system Check for gas leaks Inspect/check condensate lines and fi ttings Before starting the boiler, and during ini- 1. Inspect the condensate drain line, condensate PVC fi ttings tial operation, use a leak detector or smell and condensate trap.
  • Page 38 ® Series 4 gas-fired water boiler — Boiler Manual Startup — fi nal checks (continued) ❏ To start the boiler Check gas piping 1. Turn OFF the boiler ON/OFF switch. 1. Check around the boiler for gas odor following the proce- 2.
  • Page 39 ® Series 4 gas-fired water boiler — Boiler Manual Startup — fi nal checks (continued) Figure 38 Part number 550-100-400/0119...
  • Page 40 If throttle screw adjustment does not correct the problem, then shut down the boiler and contact Figure 40 your local Weil-McLain representative. Throttle screw adjustment must be done only by a qualifi ed technician, using calibrated test instruments. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 41 fi re, verify high fi re readings again. Restore fi ring rate to AUTO. 6. Consult your local Weil-McLain representative if acceptable results cannot be obtained for both high and low fi re. Part number 550-100-400/0119...
  • Page 42 Verifi ed control operation for space heating and DHW (if ❏ Fill out the warranty registration card and send to used) per this manual? Weil-McLain. ❏ Tested additional fi eld-installed controls? — If boiler has ❏ a low water cutoff, additional high limit or other controls,...
  • Page 43 ® Series 4 gas-fired water boiler — Boiler Manual Quick view . . . Pages 44 –47 48–49 50–51 52–55 56–57 58–64 66–92 94–98 99–107 43 43 Part number 550-100-400/0119...
  • Page 44 ® Series 4 gas-fired water boiler — Boiler Manual Gas-fi red water boiler Featuring Flexibility Ultra Models -80, -105 , -155 and -230 U-Control The U-Control responds to signals from the room ther- mostats, DHW aquastats (when used), boiler sensors (boiler return, boiler supply, system return, system supply, fl...
  • Page 45 ® Series 4 gas-fired water boiler — Boiler Manual Gas-fi red water boiler Featuring Flexibility Part number 550-100-400/0119...
  • Page 46 ® Series 4 gas-fired water boiler — Boiler Manual Gas-fi red water boiler Featuring Flexibility Ultra Models -299/310 and -399 U-Control The U-Control responds to signals from the room ther- mostats, DHW aquastats (when used), boiler sensors (boiler return, boiler supply, system return, system supply, fl ue temperature, and outdoor temperature, if used).
  • Page 47 ® Series 4 gas-fired water boiler — Boiler Manual Gas-fi red water boiler Featuring Flexibility Part number 550-100-400/0119...
  • Page 48 ® Series 4 gas-fired water boiler — Boiler Manual Prepare boiler — convert for propane Installing propane orifi ce Prepa re boiler for propane — You must turn (when required) off electrical supply to the boiler and close the external manual gas shut-off valve to isolate the Propane operation boiler during conversion.
  • Page 49 ® Series 4 gas-fired water boiler — Boiler Manual Prepare boiler — convert for propane (continued) 4. Lift the door away from boiler. Figure 45 5. Remove the air inlet silencer from the adapter: a. Models 80 and 105: See Figure 134, page 133 . b.

  • Page 50: Ultra-230

    ® Series 4 gas-fired water boiler — Boiler Manual Placing boiler — wall-mounting option Wall-mounted boilers (Ultra-80 through -399) Figure 46 1. The wall-mounting kit is NOT supplied as standard equipment with the boiler, and must be purchased separately. See below.
  • Page 51 ® Series 4 gas-fired water boiler — Boiler Manual Placing boiler — wall-mounting option (continued) Prepare boiler for wall mounting 1. Remove the jacket front panel. This will simplify lifting and han- dling the boiler when mounting. 2. When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual.
  • Page 52 ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — advanced Zoning with zone valves Figure 48 (alternate to piping shown in Figure 5, page 12 ) High-fl ow-rate/high-head-loss DHW circuits 1. For applications requiring DHW circuit fl ow rates higher than allowable for the boiler, or for high pressure-drop coil-type DHW tanks, connect the piping as in Figure 48 .
  • Page 53 ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — advanced (continued) Example system with DHW as a zone, Figure 49 zoning with circulators 1. Connect boiler to system as shown in Figure 49 when circula- tor zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop.

  • Page 54: Ultra-299/310

    ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — advanced (continued) Radiant heating applications Figure 50 1. The Ultra boiler is ideal for use in radiant heating. The Ultra boiler’s unique heat exchanger design allows it to work well even in condensing mode.
  • Page 55 ® Series 4 gas-fired water boiler — Boiler Manual Install water piping — advanced (continued) Chilled water systems Figure 51 1. Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler.
  • Page 56 ® Series 4 gas-fired water boiler — Boiler Manual Sizing dire ct-connected DHW piping Direct-connected DHW piping The closest circulator selection (from Figure 55, page 57 that can deliver 12 gpm at 22.7 feet head is either a Taco 1400 (top chart) or a Taco 0013 (bottom chart). refer to the AQUA PLUS water heater manual for Note that, if the water heater were piped as in Figure 53 , application information.
  • Page 57 ® Series 4 gas-fired water boiler — Boiler Manual Sizing dire ct-connected DHW piping (continued) Figure 55 Figure 54 (H1=Ultra boiler head loss; H2=piping head loss) Flow Temp Pipe rate rise size Taco 0011 Taco 0010 Boiler head Piping head °F Inches loss...
  • Page 58 ® Series 4 gas-fired water boiler — Boiler Manual Multiple boiler installations Placing multiple boilers Figure 56 1. Locate multiple boilers in boiler room according to: a. Figure 56 (side-to-side), or b. Figure 57 (back-to-back). c. Figure 58 (wall mounting). 2.
  • Page 59 ® Series 4 gas-fired water boiler — Boiler Manual Multiple boiler installations (continued) Manifolded combustion air option 1. Multiple Ultra boilers can use a common combustion air manifold. a. See Figure 139, page 138 for minimum cross sectional area of combined air ducts.
  • Page 60 ® Series 4 gas-fired water boiler — Boiler Manual Multiple boiler installations (continued) Easy-Fit piping installation ® 1. Main header and Easy-Fit Manifold pipe sizing. a. New system — See page 10 . b. Replacing boilers in an existing system — Without reducing size, connect system supply and return lines.
  • Page 61 ® Series 4 gas-fired water boiler — Boiler Manual Multiple boiler installations (continued) Figure 62 Legend — Figure 62 1 Flow/check valve (each boiler) 11 Check valve or backfl ow preventer, as required by applicable codes 12 Isolation valve 2 Isolation valves (when used) 13 Cold water supply 3 Cap 14 Supply water temperature control (when used)
  • Page 62 20 Boiler relief valve and discharge piping, installed per Ultra Boiler Manual 3 Caps 21 Indirect-fi red storage water heaters (Weil-McLain AQUA PLUS shown) — 4 Easy-Fit® Manifold (supply) — layout and size per page 60 Example is shown connected to one boiler of the system. Preferably, use 5 Easy-Fit®...
  • Page 63 140 – 290 gpm 4” Legend — Figure 64 Flow/check valve (each boiler) Indirect-fi red storage water heaters (Weil-McLain AQUA PLUS shown) — Example This piping is sug- is shown with reverse-return boiler-side piping using a single circulator. Alternate: gested only. The Isolation valves (when used) each water heater could have its own circulator.
  • Page 64 ® Series 4 gas-fired water boiler — Boiler Manual Multiple boiler installations (continued) Figure 65 1. Large volume systems with high mineral content in water. 2. Systems exposed to untreated quantities of makeup water. 3. Old systems severely contami- nated with scale and rust buildup inside piping and heat distribu- tion units.
  • Page 65 ® Series 4 gas-fired water boiler — Boiler Manual Venting/air piping — Massachusetts installations Instructions for the Commonwealth of Massachusetts (a) For all sidewall horizontally-vented gas-fueled equipment : The following equipment is exempt from installed in every dwelling, building or structure used in 248 CMR 5.08(2)(a)1 through 4: whole or in part for residential purposes, including those 1.
  • Page 66 2. Sidewall options (see Figure 12, page 18 , left side): a. TOP: Weil-McLain termination cap (kit included with boiler) — see page 67 for instructions. b. MIDDLE: Concentric PVC pipe (requires special kit, page 129 ).
  • Page 67 Step 9 Determine proper location for wall or roof penetration c. The Weil-McLain sidewall vent/air cap kit includes the for each termination. termination cap, inside and outside wall plates, and mounting hardware to secure the plates.
  • Page 68 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: Weil-McLain cap (cont.) Provide pipe adapters as needed where pipe size Connecting from termination to boiler is different from termination connections or 1. Install the termination as instructed in the following. Then...
  • Page 69 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: Weil-McLain cap (cont.) d. Avoid possibility of accidental contact of fl ue products with Figure 71 people or pets. e. Do not locate the terminations where wind eddies could affect...
  • Page 70 fl ue pipe and air pipe. Level the template with a spirit level. For the Weil-McLain plate, the template must be level to ensure the fl ue and air pipe will be side-to-side, as shown in Figure 74 . Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 71 5. Deburr inside and outside of pipe ends. adapter at the boiler vent connection (and at the termination if using the Weil-McLain plate or the 6. Chamfer outside of each pipe end to ensure even cement concentric termination). Use only the adapter made distribution when joining.
  • Page 72 . Most kits do not include the screens. Purchase separately A gas vent extending through an exterior wall shall not from Weil-McLain or vent kit supplier if terminate adjacent to the wall or below building exten- not included. sions such as eaves, parapets, balconies or decks. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 73 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: 3” or 4” concentric (cont.) b. The fl ue products will form a noticeable plume as they con- Figure 80 dense in cold air. Avoid areas where the plume could obstruct window views.
  • Page 74 ® Series 4 gas-fired water boiler — Boiler Manual Sidewall vent/air termination: 3” or 4” concentric (cont.) Install terminations — concentric pipes Figure 82 1. Assemble the vent termination as described for vertical concen- tric terminations, beginning on page 76 . If necessary, you can shorten the lengths of the inner and outer pipes for a shorter fi...
  • Page 75 4. Maintain clearances to termination as given below: All vent and air pipes require a a. Vent outlet must be located: . Most kits do not include the screens. Purchase separately from Weil-McLain or vent kit supplier if not included. Part number 550-100-400/0119...
  • Page 76 ® Series 4 gas-fired water boiler — Boiler Manual Vertical vent/air termination: 3” or 4” concentric (cont.) At least 6 feet from adjacent walls. 3. Partially assemble the vent termination kit in the sequence shown in Figure 89, page 78 . No closer than 5 feet below roof overhang.
  • Page 77 ® Series 4 gas-fired water boiler — Boiler Manual Vertical vent/air termination: 3” or 4” concentric (cont.) When inserting the partially-assembled termination kit Figure 87 through the roof penetration, wrap plastic or other protection over the end of the exposed assembly to prevent debris from entering the pipes.
  • Page 78 ® Series 4 gas-fired water boiler — Boiler Manual Concentric vent/air termination assembly Figure 89 Figure 90 Part number 550-100-400/0119...
  • Page 79 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT VENT: Vertical vent / sidewall air Allowable vent/air pipe materials Determine location 1. Use only the materials listed in Figure 13, page 19 . 1. Locate the vent termination using the following guidelines: 2.
  • Page 80 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT VENT: Vertical vent / sidewall air (continued) Termination and fi ttings Figure 92 1. Prepare the vent termination coupling by inserting a bird screen. Bird screens must be purchased separately. See the parts list at the end of this manual for part numbers.
  • Page 81 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT VENT: Vertical vent / sidewall air (continued) Multiple air terminations Figure 94 1. When terminating multiple Ultra boiler air connections, terminate each air connection as described in this manual. 2. Place wall penetrations to obtain minimum clearances as instructed in this manual.
  • Page 82 ® Series 4 gas-fired water boiler — Boiler Manual Install vent/air pipi ng — boiler to termination Complete termination preparation Figure 95 1. Install vent and air terminations before proceeding. See previ- ous pages for instructions. Installing vent and air piping 1.
  • Page 83 VERTICAL direct exhaust option 1. Read and follow instructions in Boiler manual, including page 65 for Massachusetts installations when applicable. Every vent pipe requires a . Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Part number 550-100-400/0119...
  • Page 84 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT EXHAUS T — Boiler room air openings Combustion air provision Special considerations The Ultra boiler can use inside air if no contaminants are pres- Tight construction ent in the boiler space. (If contaminants are likely to be present, install the boiler as a direct vent appliance, using the appropriate ANSI Z223.1 defi...
  • Page 85 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT EXHAUST — Boiler room air openings (continued) Figure 96 Air openings Ultra boiler Ultra boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction. Note the ex- appliances in room appliances in room ception below for large spaces.
  • Page 86 2. Install a bird screen in each vent pipe termination (coupling or elbow). Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Maximum piping length 1. Locate the termination such that the total vent piping from the boiler to the termination will not exceed the maximum length given in Figure 12, page 18 .
  • Page 87 ® Series 4 gas-fired water boiler — Boiler Manual DIRECT EXHAUST — Sidewall (continued) Figure 98 Figure 99 Figure 100 4. Consider the surroundings when terminating the vent: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.
  • Page 88 Insert the galvanized metal thimble (by installer) in the vent pipe hole as shown in Figure 101 . The Weil-McLain sidewall termination kit 2. Follow all local codes for isolation of vent pipe when passing supplied with each boiler includes metal through fl...
  • Page 89 2. Install a bird screen in each vent pipe termination (coupling or elbow). Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Maximum piping length 1. Locate the termination such that the total vent piping from the boil- er to the termination will not exceed the maximum length given in Figure 12, page 18 .
  • Page 90 1. Prepare the vent termination coupling ( Figure 103 ) by inserting a bird screen. Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. 2. The vent piping must terminate in a coupling as shown in Figure 103 .
  • Page 91 AL29-4C vent pipe — If using AL29-4C stain- less vent pipe, you must install a PVC-to-vent pipe adapter at the boiler vent connection (and at the termination if using the Weil-McLain plate or the concentric termination). Use only the adapter made by the vent pipe manufac- turer.
  • Page 92 6 inches of any upturn in the The Weil-McLain plate piping. termination must be installed The Weil-McLain 3” PVC before piping from the boiler to concentric termination assembly the termination. must be installed before piping Slope horizontal piping downward from the boiler to the termination.
  • Page 93 ® Series 4 gas-fired water boiler — Boiler Manual Gas piping — sizing gas lines Natural Gas: Figure 107 Pipe sizing for natural gas 1. Size gas piping from meter outlet to entrance of boiler in accor- dance with Figure 108 and Figure 109 . 2.
  • Page 94 ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — advanced secondary heat source when another heat source, — For your such as a heat pump or another boiler is available. safety, turn off electrical power supply at service ❏...
  • Page 95 2. The factory default confi guration is for “heat demand 1” 3. When possible, use the Weil-McLain Ultra low water cut-off kit to be DHW and “heat demand 2” to be space heating. listed in the back of this manual. It includes a probe-type low water For factory default operation: cut-off and provides a simple harness connection for the wiring.
  • Page 96 ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — advanced (continued) Figure 111 Part number 550-100-400/0119...
  • Page 97 ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — advanced (continued) Figure 112 Part number 550-100-400/0119...
  • Page 98 ® Series 4 gas-fired water boiler — Boiler Manual Field wiring — advanced (continued) Add itional limits Outdoor temperature sensor 1. The U-Control allows connection of external limit controls, 1. The U-Control provides programmable options when both for manual reset and for automatic reset operation of the using an outdoor temperature sensor.
  • Page 99 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (radiant slab, etc.) — use the Ultra boiler 1. Use this setting to adjust the outdoor sensor temperature control as the only means of water tem- to account for solar or other effects that would cause the perature regulation for low-temperature sensor to read incorrectly.
  • Page 100 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) f. An alternate method is to daisy chain the other a. Outdoor temp for max target means the outdoor temperature boilers. That is, connect the output of each to the at which the target temperature reaches its maximum value.
  • Page 101 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) Figure 114 U-Control system types and preset parameters 8-character 3-char ADVANCED SETUP – ADVANCED SETUP – CIRCULATOR EXERCISING FREEZE PROTECTION CIRCULATORS 1. For each circulator, select whether you want the U-Control to 1.
  • Page 102 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) Figure 115 U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data BOILER SETTINGS BOILER MODEL ##### HIGH ALTITUDE ###...
  • Page 103 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data SET DATE AND TIME SET YR/MN/DAY/HR/MIN DIAGNOSTICS...
  • Page 104 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) Figure 116 U-Control setup options Boiler Model 80, 105, 155, factory . Adjusts blower speeds 230, 299, 310, and fl ame sense (Display will show “HA” after the model number if high altitude has been selected, below.) High Altitude yes or no...
  • Page 105 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) U-Control setup options Max On Time minutes Longest time boiler will satisfy this system before switching to an active lower priority Min On Time minutes Time boiler will satisfy this system before switching to the next active priority Boost Interval...
  • Page 106 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) Figure 117 U-Control diagnostic inform ation Status Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfi ed, post purge, Warm Weather Shutdown, Trouble System Supply °F data...
  • Page 107 ® Series 4 gas-fired water boiler — Boiler Manual U-Control operation and setup — advanced (continued) U-Control diagnostic inform ation yes or none data Choose this to view the details of manual reset lockouts Manual Reset Auto Reset yes or none data Choose this to view the details of auto reset lockouts Inputs...
  • Page 108 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
  • Page 109 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup HANDLING CERAM IC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS REMOVING BURNER GASKET or COVER PLATE INSULATION . This kit includes a heat exchanger cover plate gasket, burner gasket (80 The Ultra burner gasket (models 80 and 105 only), new ignitor, and ignitor gasket.
  • Page 110 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. Loosen condensate trap line hose clamps and remove trap started annually, at the beginning of the line. heating season, only by a qualifi ed service 2.
  • Page 111 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup (continued) 4. Inspect automatic air vents and air separators. Remove air vent caps Inspect ignition electrode and briefl y press push valve to fl ush vent. Reinstall caps. Make sure vents do not leak.
  • Page 112 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup (continued) Check burner fl ame Check fl ame signal 1. Navigate to Diagnostics/Inputs on the U-Control display (see The boiler contains ceramic fi ber materials. Use care when handling these materials per Figure 115, page 102 ).
  • Page 113 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup (continued) 4. If fl ame signal still remains low, inspect the vent and air 7. Write down the blower RPM value. It should be within 200 piping. Then inspect the heat exchanger, following the proce- RPM of the value listed in Figure 121 .
  • Page 114 ® Series 4 gas-fired water boiler — Boiler Manual Annual startup (continued) Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify fl ow as in the following warnings, excerpted from a relief valve manufac- turer’s warning label.
  • Page 115 ® Series 4 gas-fired water boiler — Boiler Manual Tro ubleshooting Reinstall boiler jacket front door Before servicing and making connections . . . Reinstall boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room.
  • Page 116 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) Check the following: Do not jumper fuse or replace with any fuse except as specifi ed. Failure to comply 1. Make sure thermostat is calling for heat and con- could result in severe personal injury, tacts (including appropriate zone controls) are death or substantial property damage.
  • Page 117 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. U-Control fault indications 1. The U-Control provides diagnostic information for below the display illustration lists manual reset conditions and how both automatic reset conditions and manual reset to reset from them.
  • Page 118 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) Figure 125 U-Control Error Condition Log The U-control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS” by selecting “ERRORS.” The control will display the following information: Records the number of internal control faults Select and press the enter key to reset this count...
  • Page 119 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) (continued) Condition Diagnostics Corrective Action(s) Display Nothing Control is not receiving 120V Check service switch and/or Turn on service switch to power boiler. is shown power. circuit breaker to boiler turned in display is on.
  • Page 120 Manual reset is required if the Inspect vent system for abnormal wear or damage. temperature rises above 225°F. Reset using manual reset screen Contact Weil-McLain Technical Support. on display. Occurs when dual Automatically resets when Follow procedure for above for SHORT and OPEN sensor conditions temperature sensors values sensors are within 10ºF.
  • Page 121 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting Troubleshooting (continued) (continued) (continued) Condition Diagnostics Corrective Action(s) Display Occurs when display Automatically resets when Check for a loose connection at the molex plug on the control and communications out for 30 communication is re- connection on the back of the display.
  • Page 122 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) (continued) Condition Diagnostics Corrective Action(s) Display Blower unable to reach Automatically resets after 1 hour Check wire harness for loose connections and pin engagement at blower required speed or does not or can be reset by using manual connections, chassis mount connection through sheet metal cabinet, reach 0 RPM when turned off...
  • Page 123 ® Series 4 gas-fired water boiler — Boiler Manual Troubleshooting (continued) (continued) Condition Diagnostics Corrective Action(s) Display The U-Control has detected Automatic retry when condition Check wire harness connections between gas valve and U-Control. a problem with it gas valve exists.
  • Page 124 ® Series 4 gas-fired water boiler — Boiler Manual Near boiler pipe size: Boiler circulator model: DHW tank (yes/no): DHW direct/system: Dhw model: Dhw pipe size: DHW circulator model: Is there air in system?: Additional heat demand: Additional heat demand: Additional heat demand: Part number 550-100-400/0119...
  • Page 125 2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instruc- 4. Use ONLY the cleaning product available from Weil-McLain, tions. Over-oiling will damage the circulator. Sentinel X400. See the Repair Parts section at the end of this manual for ordering information.
  • Page 126 ® Series 4 gas-fired water boiler — Boiler Manual Maintenance (continued) For the fi rst 5 years, vacuum or rinse heat exchanger with water only. No tool cleaning is necessary. Accessing & cleaning heat exchanger: Figure 126 Ultra-80 and Ultra-105 Only 1.
  • Page 127 ® Series 4 gas-fired water boiler — Boiler Manual Maintenance (continued) Accessing & c leaning exchanger: Ultra-155, Figure 128 -230, -299/310 and -399 Only 1. Close the external manual gas valve. 3. Disconnect the fl exible gas line at its fl are fi tting. 4.
  • Page 128 Results from using modifi ed or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists. . Use care when handling these materials per instructions on page 109 of this manual.
  • Page 129 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 130 Description Part Number CHEMICALS BOILER ACCESSORIES AND CONTROLS VENT / AIR TERMINATIONS CONDENSATE HANDLING Part number 550-100-400/0119...
  • Page 130 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 131 Boiler Part Boiler Part Description Description models number models number Flue outlet pipe adapter 3” Jacket front door 383-500-135 80/105 560-907-771 3” Boiler leg kit (4 required) 383-500-065 560-907-771 Screw fl...
  • Page 131 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 132 Part Description Number Ultra U-Control module 383-500-658 Transformer, 120V/24V 383-500-628 Display board assembly (includes plastic and display screen) 383-500-756 On/off power switch 383-500-205 Flue temperature sensor replacement kit 383-500-600 System temperature sensors (2 required) 383-500-601...
  • Page 132 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 133 Boiler Item Description Part Number Models 80LP & plugs 80LP Part number 550-100-400/0119...
  • Page 133 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 134 Part number 550-100-400/0119...
  • Page 134 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 135 Boiler Part Description models number Heat exchanger replacement kit - Heat 383-500-673 exchanger, cover plate, burner, electrode, 383-500-674 Boiler Part Description water sensors, compression fi ttings, models number condensate fi...
  • Page 135 ® Series 4 gas-fired water boiler — Boiler Manual Replacement parts (continued) Figure 136 Boiler Part Boiler Part Description Description models number models number Heat exchanger replacement kit - Heat 299/310/399 383-500-675 16 Gas valve/venturi kit - Gas valve, venturi, 299/310 383-500-390 exchanger, cover plate, burner, electrode,...
  • Page 136 ® Series 4 gas-fired water boiler — Boiler Manual Dimensions Figure 137 Notes Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-299/310/399). See page 10 for recommended piping sizes. Wall-hung boiler option — water piping and gas pipe can only be routed through top of enclosure using wall-mounting kit. See page 5 for mounting instructions.
  • Page 137 2.10 Notes As an Energy Star Partner, Weil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy effi ciency. NOTE: Adjusting boiler fi ring rate will affect AFUE rating. Based on standard test procedures prescribed by the United States Department of Energy.
  • Page 138 ® Series 4 gas-fired water boiler — Boiler Manual Ratings — Multiple Ultra Series 4 boilers Figure 139 Foundation size Manifolded Total Boiler combustion Side-to-side Back-to-back Heating water Boilers in system H.P. air duct arrangement arrangement input capacity ratings Model Ultra – size (height 2”...
  • Page 139 Based on standard test procedures outlined by DOE for individual boilers. Net AHRI ratings are based on piping and pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Foundation sizes in Figure 139 provide 6 inches between boilers and 2 inches from boiler to edge of foundation.
  • Page 140 ® gas-fired water boiler — Boiler Manual Series 4 gas-fired water boiler — Boiler Manual Installation and Service Certifi cate Boiler Model Series CP Number Date Installed ❏ Installation instructions have been followed. BTU Input ❏ Check-out sequence has been performed. ❏...

This manual is also suitable for:

Ultra-105Ultra-80Ultra-299Ultra-310Ultra-399Ultra-230 ... Show all